Bike 'printed' using layers of powdered nylon

It's hard to understand the thinking behind building a bike to show people how aircraft of the future might be made, especially when the bike ends up looking almost retro in a 1970s this-is-what-the-future-will-look-like sort of way.

But regardless of its appearance, the Airbike is an impressive accomplishment, not least because it was "grown" fully assembled. Well, almost. By "grown" its creators at European Aerospace and Defence Group (EADS) in Bristol, UK, really mean printed.

(Image: EADS)

Using a type of 3D printing technique called additive layer manufacturing (ALM), a high power laser is fired from above to melt a powdered material in a container. As the laser marks out a pre-programmed shape in the powder, the melted nylon solidifies making the first layer of the object that is to be printed.

The machine then sprinkles another layer of powder on top and the laser makes another pass, allowing progressive layers of the object to be built up. The printer eventually creates a 3D object - even including functional moving parts - that has been built layer by layer from scratch.

While the Airbike is made up of six separately printed pieces, some contain moving parts, such as the bearings in both of the wheels. But EADS's interest in this technology lies more in how it can potentially save weight.

By having more flexibility about the 3D structure of aircraft components it is possible to print them out of anything from metals to carbon-reinforced plastics with the same strength as traditionally machined parts, but up to 65 per cent lighter.

How unfortunate then that the Airbike looks so incredibly uncomfortable to ride. Best stick to designing aircraft, guys...